Knock down universal chimney cap

ABSTRACT

A chimney cap that permits compact storage and quick installation is described. The chimney cap is at least partially hinged, which permits the cage to be quickly set up from a folded condition. This is accomplished by hingeably coupling the sides of the cage to the bottom of the cage. The sides are coupled together by inserting a pin into concentric knuckles formed when corresponding edges are joined together. The folded product may be stored for transport or sale in a substantially flat box.

BACKGROUND

The present invention relates generally to a chimney cap for protecting the upper open end of a chimney flue from the ingress of undesirable elements.

Chimney caps may be used to prevent the ingress of undesirable elements into the upper end of the chimney flue. For example, the undesirable elements may include birds, squirrels, and rain. Chimney caps can also be used to prevent the egress of embers from the upper end of the chimney flue.

The prior art does not permit compact and convenient handling of chimney caps and/or components for shipping and storage. It would be desirable to store new caps in flat storages boxes. Such a storage system can provide various advantages related to space. For example, flat boxes would save a chimney sweep space in his or her vehicle. Chimney cap components stored individually in flat boxes can also save retailers and wholesalers storage space. Furthermore, manufacturers using caps and components that will fit into flat boxes can reduce material handling and shipping costs, packaging requirements and storage space.

There is known in the related art, a chimney cap having a four-sided cage having rectangular cage components. See, for example, U.S. Pat. No. 4,549,473 (Alexander et al.), U.S. Pat. No. 4,535,686 (Hisey), U.S. Pat. No. 4,334,360 (Simmons et al.) and U.S. Pat. No. 2,976,796 (Anthony et al.). The resulting caps generally could not be easily stored because of their rectangular shape. Additionally, in certain chimney caps the studs used to secure the lid to the top of the cage are secured, e.g., welded, to brackets and the brackets are secured, e.g., welded, to the top of the cage. These brackets are also typically substantially right-angled in shape, having one leg substantially parallel to the side of the cage and one leg extending substantially perpendicular from the side into the interior of the cage. Consequently, these inconsistently shaped trapezoidal cages with angled brackets further made compact storage difficult.

Therefore, it would be desirable to have consistently shaped chimney caps that permit compact storage.

Additionally, it would be desirable to have compactly stored caps that permit relatively quick, easy setup.

SUMMARY

The invention relates to a chimney cap that is reasonably uniformly manufactured and permits compact storage. The invention also relates to a compactly stored chimney cap that permits relatively quick and easy setup. In one exemplary embodiment, a chimney cap has a lid and a cage. The cage is five sided and collapsible so that the cage can be stored substantially flat and easily setup on location. The side walls of the cage are hinged to the base area of the cage enabling the side walls to be folded over and/or under the base area for compact storage. The cage is setup by unfolding the side walls so that all the side walls are on the same side of the base of the cage. Each side wall has a hinge leaf configured such that corners of adjacent walls are coupled together by inserting a pin through the leaves.

These and other features and advantages of the invention will be more readily understood from the following detailed description of the invention which is provided in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a chimney cap according to an exemplary embodiment of the present invention.

FIG. 2 is a plan view of the chimney cage portion of the chimney cap of FIG. 1 in an unfolded condition.

FIG. 3 is a perspective view of the lid in the cap of FIG. 1.

FIGS. 4(a) and (b) are orthogonal views of a securing mechanism used in the installation of the cap of FIG. 1.

FIG. 5 is a perspective view of an assembled cap of FIG. 1 installed on a flue.

FIGS. 6(a) and (b) are perspective views of a folded cap of FIG. 1.

FIG. 7 is an exploded perspective view of chimney cap according to another exemplary embodiment of the present invention.

FIG. 8 is a perspective view of another securing mechanism used in the installation of the cap of FIG. 1 or 7.

FIGS. 9(a)-(c) are orthogonal views of the securing mechanism of FIG. 8.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific exemplary embodiments of the invention. These embodiments are described in sufficient detail to enable those of ordinary skill in the art to make and use the invention, and it is to be understood that other changes may be made to the specific embodiments disclosed without departing from the spirit and scope of the present invention.

FIGS. 1 and 2 show chimney cap 100 according to an embodiment of the present invention which includes a cage 110 and a lid 140. The cage 110 is a substantially square shaped figure having sides with perforations that permit the egress and ingress of limited elements. The lid 140 is disposed above the cage 110 and serves as the top of the chimney cap 100 and the lid 140 is secured to the sides of the cage 110.

As seen in FIGS. 1 and 2 the cage 110 is formed from a perforated material with perforations sufficiently large to permit air flow through the cage, but sufficiently small enough to reasonably prevent embers from egressing the chimney flue through the cage 110 and also to prevent the ingress of undesirable elements, e.g., small animals. The cage 110 is initially generally either substantially square or rectangular in shape. The cage 110 has four side walls 170, 180 that may all be of substantially identical dimensions and contour thereby forming a square-like cage. Alternatively, the side walls 180 may both be either larger or smaller than the side walls 170 thereby presenting a rectangular cage.

The bottom portion, floor, of the cage 110 is provided with four flanges: a first pair of flanges 172 and a second pair of flanges 182. As seen in FIG. 2, the flanges 172, 182 are configured in a square shape in substantially a single plane with flanges 182 on the top and bottom sides 1212, 1210 of the square 1208 and the flanges 172 on the right and left sides 1216, 1214 of the square 1208. Thus portions of flanges 172, 182 overlap. In an exemplary embodiment, parts of the overlapping flange portions are spot welded 1202 together.

Still referring to FIG. 2, the flanges 172, 182 extend in-part substantially perpendicular to the respective side walls 170, 180 to which the flanges 172, 182 are coupled through a respective hinge 190, 192. For example, as seen in FIG. 2, a flange 172 is coupled to one leaf of hinge 190 and the other side of hinge 190 is coupled to the bottom of side wall 170. As also seen in FIG. 2, a flange 182 is coupled to one leaf of hinge 192 and the other side of hinge 192 is coupled to the bottom of side wall 180. In an exemplary embodiment, each hinge 190, 192 extends over substantially the entire length of the edge formed by a side and its corresponding flange. The flanges 172, 182 serve to strengthen and support the side walls 170, 180. In an exemplary embodiment, one leaf of hinge 190 is spot welded to flange 172 and the other leaf of hinge 190 is spot welded to side wall 170. Additionally, one leaf of hinge 192 is spot welded to flange 182 and the other leaf of hinge 192 is spot welded to side wall 180. In a preferred embodiment, the perforated material used to form the side walls 170, 180 and flanges 172, 182 is expanded eighteen (18) gauge AISI 304 or 304L stainless steel or galvaneal coated carbon steel mesh. Other suitable material may also be used.

Each side edge 1170 of side wall 170 is coupled to a leaf 194 of a hinge 1195 (FIG. 1) that, in a preferred embodiment, extends substantially along the length of the side edge 1170 of side wall 170. Each side edge 1180 of side wall 180 is coupled to a leaf 196 of a hinge 1195 that extends substantially along the length of the side edge 1180 of side wall 180. In an exemplary embodiment a leaf 194, 196 is spot welded to a respective side wall 170, 180. In an exemplary embodiment, the distance between hinge centers on each side of a side wall 170, 180 is thirteen and three-eighths inches (13⅜″).

Referring to FIG. 2, the sides walls 170, 180 and flanges 172, 182 of the cage 110 are derived from flat, perforated metal portions; e.g. expanded metal or metal mesh. In an exemplary embodiment, to form a substantially square shaped cage 110, each side wall 170, 180 is formed from an approximately nine by thirteen inch (9″×13″) piece of expanded metal. Additionally, each flange 172 is formed from an approximately four by twelve inch (4″×12″) piece of expanded metal and each flange 182 is formed from an approximately four by thirteen inch (4″×13″) piece of expanded metal. In an exemplary embodiment, each hinge 190, 192 is approximately twelve inches (12″) and placed substantially centered on each respective side edge. In a preferred embodiment, hinge 190 is oriented so that side wall 170 is folded over the top of a plane substantially formed by the flanges 172, 182 and hinge 192 is oriented so that side wall 180 is folded under the bottom of a plane substantially formed by the flanges 172, 182. These dimensions are provided to illustrate an exemplary embodiment of the invention. The invention may be constructed with other suitable dimensions. In a preferred embodiment, the diamond shaped mesh used to construct the side walls 170, 180 is oriented with a long dimension of the diamond in a horizontal direction. Such orientation results in the smoother points of the diamonds exposed at the top 1196, 1194 of the side walls 170, 180. Similarly, the diamond shaped mesh used to construct the flanges 172, 182 is oriented with a long dimension of the diamond in a direction substantially parallel to the long sides of the respective flanges. Such orientation results in the smoother points of the diamonds exposed at the interior edge of the flanges 172, 182. Reducing the sharp ends can reduce the likelihood that a worker, e.g., a chimney installer or chimney sweep, or a tool used by a worker, gets snagged on an exposed top 1196, 1194 or on an interior edge of flange 172, 182. In a preferred embodiment, five-eighths inch (⅝″) apertured mesh is used.

Each leaf 192, 194 is configured such that when side walls 170, 180 are positioned to form an edge, the knuckles 1191 of associated leafs 192 and 194 are interleaved and a pin 160 (FIG. 1) is inserted to form a hinge. In an exemplary embodiment, leaves 192 and 194 are configured such that the top edges 1196, 1194 of side walls 170, 180 are at substantially the same height. Although the invention is described with reference to each side wall 170, 180 being adapted to be coupled to a neighboring side wall 180, 170 by interleaving knuckles 1191 with the neighboring side 180, 170 and securing with the insertion of a pin 160 down substantially the length of the combined knuckles 1191, the invention is not so limited. For example, neighboring sides 170, 180 can be secured with the use of locking tabs.

In an exemplary embodiment, a fastening stud 310 is attached to each side wall 170 at the top 1196. As seen in FIG. 2 (and in FIG. 1) each stud 310 is resistance welded to a placement pad 312, which in turn is welded to a respective side wall 170. The studs 310 are positioned on the side walls 170 to correspond to the openings, e.g., holes, 146 in the lid 140 (FIG. 3). In a preferred embodiment, the placement pad 312 is a three (3) inch by one and a half (1½) inch triangle of twenty four gauge stainless steel and is fastened to the exterior of each respective side 170.

The lid 140 is shown in greater detail in FIG. 3. The lid 140 is preferably sufficiently configured to prevent weather elements such as rain, snow or the like, from directly downwardly accessing a chimney flue. The lid 140 has a central flat area 142 and four sloped eaves 144. The eaves 144 are sloped top to bottom which minimizes the congregation of elements on the top side of the lid 140 and prevents elements from directly rolling off of the top side of the lid 140 into a chimney flue or the cage 110. In a preferred embodiment, the lid 140 is formed of twenty-four (24) gauge stainless steel or galvaneal coated carbon steel. The perimeter of the lid 140 has a one hundred and eighty degree (180) rollover that is three-eighths (⅜) of an inch, where the roll is formed towards the underside of lid 140. Each eave 144 is a three (3) inch overhang that is sloped at a forty-five (45) degree downward angle. The lid 140 also has two (2) openings 146, i.e., holes, that are used to secure the lid 140 onto the cage 110.

After a lid 140 is placed over the chimney cage 110 and the fastening studs 310 protrude through holes 146, wing nuts 149 (FIG. 1) are screwed onto fastening studs 310 to secure the lid 140 to the chimney cage 110. It is preferable that a washer 148 is placed over the fastening stud 310 and between the top of the lid 140 and the bottom of the wing nut 149.

A securing mechanism 130 secures the chimney cage 110 to a flue 50. As seen in FIG. 4(a), a securing mechanism 130 is approximately “C shaped” having sides 403, 405, and 407 and a flange 401. The flange 401 extends roughly perpendicular from side 403 in the direction of side 407. In a preferred embodiment flange 401 has one side 402 (FIG. 4(b)) that is approximately concave shaped which can aid the securing mechanism 130 in grasping a surface of a flue 50. The side 405 has a hole 413 through which a mounting stud 135 is extended away from the surface of side 405. In an exemplary embodiment, the mounting stud 135 extends three eighths of an inch (⅜″) from the surface 405 and is secured to the side 405 by a right angle weld stud 411. Side 407 has a hole 408 through which a securing screw 134 (FIG. 1), e.g., having a pointed end, is used to fasten the securing mechanism 130 to a flue 50. On the interior surface of side 408 is a nut 409; the aperture of nut 409 is aligned with hole 408, both of which are adapted to receive the screw 134. In an exemplary embodiment, the nut 409 is slab welded to the inside surface of side 408. In an exemplary embodiment, flange 401 is one half inch (½″) in length, side 403 is one and nine-sixteenth inches (1 9/16″) in length, side 405 is one and fifteen-sixteenth inches (1 15/16″) in length, and side 409 is one and one-sixteenth inches (1 1/16″) in length, and the sides and flange are one and three-eighths inches (1⅜″) in width. Longer lengths of side 403 can increase the flexibility of the securing mechanism 130 and consequently decrease the strength of the securing mechanism 130. These dimensions are provided to illustrate an exemplary embodiment of the invention. The invention may be constructed with other suitable dimensions.

The size and shape of a flue 50 may vary. For the chimney cap 100 to be effective, ideally the aperture of the flue 50 fits within the bottom of the cage 110.

The chimney cap 100 is compactly stored by folding the chimney cage 110 into a reasonably low profile folded condition. A pair of sides is folded over the top of a plane substantially formed by the flanges 172, 182 (FIG. 2) and by folding the other pair of sides under the bottom of the plane substantially formed by the flanges 172, 182. In a preferred embodiment, hinge 190 is such that the significant portion of the knuckles of hinge 190 is on the upper or top surfaces of side wall 170 and flange 172. As such, side wall 170 is folded over the top of a plane substantially formed by the flanges 172, 182. Hinge 192 is such that the significant portion of the knuckles of hinge 192 is on the lower or bottom surfaces of side wall 180 and flange 182. As such, side wall 180 is folded under the bottom of a plane substantially formed by the flanges 172, 182.

FIG. 6(a) shows a chimney cap 100 ready for storage or installation. As seen in FIG. 6(a), the side walls 170, 180 are folded over and/or under the floor of the cage 110. In an exemplary embodiment, as seen in FIG. 6(a), the side walls 170, 180 are folded substantially over and/or under the floor of the cage 110 resulting in a reasonably flat, compact cage 110. The height of the folded cap is less than 25% of the height of the assembled cap 100. A lid 140 can be placed over the folded cage 110. In an exemplary embodiment, the folded cage 110 fits substantially within a well 143 (FIG. 3) formed by the underside of the lid 140.

A folded cage 110 with a lid 140 can be placed in a flat cardboard box 600 as seen in FIG. 6(b). Associated hardware, e.g., the four securing mechanisms 130, the four pins 160 and other fasteners (e.g., four wing nuts 131, four washers 132, two wing nuts 149 and two washers 148), can be placed in the box 600 as well. In an exemplary embodiment the box 600 is not substantially bigger than the size of the folded cage 140 and lid 110—the box 600 is approximately twenty inches long by twenty inches wide by two and one half inches tall (20″×20″×2.5″). The height of the box 600 is preferably less than 25% of the width of the box 600. Thus the box 600 may have the size and shape of a conventional “pizza box” with its substantially square-shaped top and low profile. In an exemplary embodiment, the box 600 may also have a handle 603 for carrying the box. In an exemplary embodiment, the associated hardware is contained in a plastic bag (not shown), which would increase the likelihood the hardware will remain with the cap 100 when need for use later. This knock down chimney cage 110 design permits storage in a compact sized box 600 that reduces the need for storage space for the chimney cap 100 with all of its component parts as described above. In another aspect, a folded cage 110 with a lid 140 can be placed in a plastic bag rather than a flat, cardboard box. In an exemplary aspect, the plastic bag is see-through and slightly larger than the size of the folded cage 110 with a lid 140 with room to also contain the associated hardware.

The chimney cap 100 is quickly set up for installation by removing the lid 140, the cage 110 and component parts from the box 600. The securing mechanisms 130 are secured to a chimney flue 50 with the screw 135 positioned in an upward direction. The screws 134 are tightened thereby firmly securing the securing mechanisms 130 to the flue 50 such that the mounting studs 135 extend in an upward direction. The chimney cage 110 is unfolded and configured into a box-like arrangement such that coinciding knuckles 1191 of leaves 194, 196 are interleaved. Pins 160 are placed into the opening of the knuckles 1191 and extend substantially the length of the leaves 194, 196 to form a hinge 1195 and mechanically couple the corresponding sides 170, 180 of the cage 110. The cage 110 is placed appropriately over the aperture 45 of the flue 50, such that mounting studs 135 protrude through openings of expanded metal in the bottom of cage 110. Wing nuts 131 are screwed onto mounting studs 135 to secure the chimney cage 110 to the flue 50. It is preferable that a washer 132 is placed over the securing stud 135 and between the top of the bottom of the cage 110 and the bottom of the wing nut 131. A lid 140 is secured to the chimney cage 110 as described above. An additional advantage of the bottom of the cage 110 having a multitude of openings in the expanded metal is that the cage 110 can be easily re-oriented on the securing mechanisms 130 as the position and placement of the securing mechanisms 130 can differ on each flue 50.

FIG. 5 shows a perspective view of an assembled cap 100 installed on a flue 50. As seen in FIG. 5, the lid 140 is secured to the top of the cage 110 and the cage 110 is secured to the flue 50. The flue 50 may be any appropriate flue of a home, business, or industrial exhaust.

FIG. 7 shows a chimney cap 700 according to another exemplary embodiment of the present invention which includes a cage 710 and a lid 740. Chimney cap 700 differs from cap 100 in that cap 700 is substantially more rectangularly shaped, e.g., sides 780 are substantially longer than sides 770.

FIG. 8 shows the chimney cap 100 of FIGS. 1-6 in another aspect. In this aspect a mounting strongback 820 and bracket 830 are shown in place of securing mechanisms 130 to secure a cage 110 to a flue 50. The strongback 820 is a slotted metal portion with a channel 823 and a hole 821. The strongback 820 is placed channel side down across the bottom of a cage 110, substantially in the middle of the cage 110 both in terms of length and width, effectively ‘bridging’ a flange 172 on one side with a flange 172 on the opposite side of the cage 110. In a preferred embodiment, the strongback 820 is formed from twelve gauge stainless steel, is twelve inches (12″) long, having a channel 823 one inch (1″) across with one half (½″) side walls of the channel 823 and is welded to flanges 172.

FIGS. 9 (a)-(c) show a portion the bracket 830 of FIG. 8 in greater detail. As seen in FIGS. 9(a) and (b), a securing mechanism 830 is shown to be a V-type bracket assembly. The securing mechanism 830 has a V-shaped bracket 856 comprising a rod 850 coupled to one end of a metal portion 881 which is coupled on the other end of metal portion 881 to two metal portions 882. Metal portion 882 has two legs 891, 892 and in a preferred embodiment metal portion 882 is bent resulting in an acute angle between legs 891, 892 of 30 degrees. The other end of metal portion 881 is sandwiched between metal portions 891. As seen in FIG. 9(c), a coupling nut 854 is attached by its exterior at each end of the metal portion 882 such that the hole of each nut 854 is substantially five (5) degrees 857 off parallel, in a radial direction, to metal portion 882. Two threaded rods 852 (FIG. 8) are threaded into a respective coupling nut 854. A wing nut 862 is threaded onto the rod 850 above a washer 872 and is used to secure the cage 110 through the strongback 820 to the flue 50.

In a preferred embodiment, the bracket 856 is constructed of twelve gauge stainless steel and is at a transverse angle from the plane perpendicular to the rod 850. The threaded rods 852 are at least six (6) inches in length and the threaded rod 850 is at least four (4) inches in length. Rod 850 is two and one-half inches long (2½″) and three-eighths in diameter. Metal portion 881 is four and one-half inches (4½″) by one inch (1″). Metal 882 is four and one-half inches (4½″) by one inch (1″) with the bend between leg 891 and leg 892 at two and one-half inches (2½″). Although described with reference to a bracket assembly 830, other types of securing mechanisms can be used. For example, a securing mechanism can be used like that described in Daniels U.S. patent application Ser. No. 10/634,753.

The cage 110 is adapted to be disposed with a portion of its bottom to be within a flue 50 which is within a chimney 51. The securing mechanism 830 secures the cage 110 to the flue 50.

Therefore, a chimney cap of the present invention is provided that is compactly stored and easily set up for use and installation. The use of folding sides increases the compact storage capabilities. The compacted cap reduces the amount of storage space (e.g., for wholesalers, distributors, retailers, installers) required for the cap. Additionally, because part of the cost of shipping a product is based on the dimensions of the shipping box, the compact design of the chimney cap reduces shipping costs, particularly when shipped by air. The use of easily coupled corners of a cage, e.g., through the insertion of pins into the interleaved knuckles, permits the cage to be field installable by an installer or homeowner who doesn't have to perform significant work, such as welding during set up, to couple the sides.

While the invention has been described and illustrated with reference to specific exemplary embodiments, it should be understood that many modifications and substitutions can be made without departing from the spirit and scope of the invention. Although the embodiments discussed above describe preferred angles, size, shape, and specific numbers of sides, bends, fasteners, etc. the present invention is not so limited. For example, the dimensions are provided to illustrate an exemplary embodiment of the invention. The invention may be constructed with other suitable dimensions. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the claims. 

1. A chimney cap for covering a flue for preventing ingress of undesirable elements into said flue, said chimney cap comprising: a lid; and a cage for supporting said lid, said cage having hinged sides.
 2. A chimney cap as in claim 1, where said sides are configured to fold substantially flat.
 3. A chimney cap as in claim 2, where said folded cage is smaller than a length and width of said lid.
 4. A chimney cap as in claim 3, where said folded cage is configured to fit substantially within a well formed by the underside of said lid.
 5. A chimney cap as in claim 4, wherein said cap is adapted to be placed on said flue, said flue having a first flue size and a first flue shape.
 6. A chimney cap as in claim 5, wherein said cap is adapted to be placed on a second flue said second flue having a second flue size and a second flue shape, said second flue size being different from said first flue size.
 7. A chimney cap as in claim 1, wherein one of said sides is adapted to be easily coupled without welding to another of said sides.
 8. A chimney cap as in claim 1, wherein one of said sides is adapted to be coupled to another of said sides by inserting a pin into apertures formed by aligned knuckles from said respective one and another of said sides.
 9. A chimney cap as in claim 1, wherein one of said sides is adapted to be coupled to another of said sides by manipulation tabs formed by aligned edges from said respective one and another of said sides.
 10. A chimney cap as in claim 1, wherein said sides are formed from perforated metal.
 11. A chimney cap, comprising: a bottom side; a first pair of sides hingeably coupled to said bottom side; and a second pair of sides hingeably coupled to said bottom side.
 12. The cap of claim 11, further comprising a lid for covering said cage, said lid being adapted to be fastened to the top of said cage.
 13. The cap of claim 12, wherein said cage further comprises a plurality of studs, each said stud disposed in a location of said cage to secure said lid to said cage.
 14. The cap of claim 11, further comprising a securing mechanism adapted to secure said cage to a flue.
 15. The cap of claim 11, wherein said first pair of sides is substantially similar in size to said second pair of sides.
 16. The cap of claim 11, wherein said second pair of sides are wider in size than said first pair of sides.
 17. The cap of claim 11, wherein said cap includes substantially flat perforated rectangularly shaped expanded metal.
 18. The cap of claim 17, wherein a portion of said cage is adapted to fit on top of said flue.
 19. A method of assembling a chimney cap, comprising the steps of: removing said chimney cap from a box; subsequently, unfolding sides of said chimney cap; coupling adjacent sides of said chimney cap; and placing a lid on said sides.
 20. A packaged chimney cap product, said packaged product comprising: a box having a width greater than its height; and a folded chimney cap located within said box. 